Simulated ceramic tile-like mosaic construction



March 23, 1965 1. R. CHURCH ETAL 3,174,893

SIMULATED CERAMIC TILE-LIKE MOSAIC CONSTRUCTION Filed Jan. 17, 1961ikili FIG.

INVENTORS.

C C c IDELLA R. CHURCH DOUGLAS 0. DEAN F/G.3 BY

ATTORNEYS 3,174,893 SIMULATED CERAMIC THEE-LIKE MOSAIC CQNSTRUCTHGNlldella R. Church, 200 Green Valley Road, Suisun City,

Calif., and Douglas D. Dean, Suisun City, Calif.

(Box 625, Fairlield, Caiif} Filed .ian. 17, 1961, Ser. No. 83,205 6Claims. (Cl. 161-5) This invention relates to mosaics. Moreparticularly, it relates to a novel simulated ceramic tile-like mosaicconstruction and to the method of preparation thereof.

In recent times, mosaics, both in their form as Works of art as well asitems of utility appear to have enjoyed increasing popularity. However,ceramic mosaics are generally expensive, primarily because they requireconsiderable skill and human labor in their construction.

It is a principal object of the present invention to provide a simulatedceramic mosaic tile-like construction from readily available andinexpensive materials, such as, for example, paper board tile piecesembedded within a layer or coating of substantially transparentsynthetic resin. In the particular embodiment of the invention to bedescribed in more detail hereinafter, we teach how it is possible tofabricate a remarkably realistic simulated mosaic tile constructionusing as the base materials a conventional jig saw puzzle made ofchip-board, cardboard, or a similar heavy paper stock, and a clearpolyester type resin. As will more fully be described, the jig-sawpuzzle is assembled in the usual manner on a fiat table surface,whereupon the liquid resin is poured and spread directly over the upperface of the puzzle to form a relatively thick coating over the entiresurface. We have found that some of the resin will separate or run downbetween the puzzle pieces and that this action produces a multiplicityof results in reference to determining the ultimate physical and visualcharacteristics of the end product. More specifically, the resin will ofcourse form a grouting in the hairline cracks and sufficient quantitiesof the liquid will also seep under at least the marginal edges of thejig-saw pieces to permanently bond the latter to the table surface onwhich the puzzle has been prepositioned. The flow or seepage of theresin into the hairline cracks also results in each puzzle or tile piecebeing coated with a thinner layer of resin adjacent its marginal edgesthan at its center portions. Therefore, when the clear resin dries andhardens, each of the individual puzzle or tile pieces is formed with arounded crown of resin coating which creates highlights and shadows thatvery realistically simulate the rounded or crowned surface contour ofactual ceramic tile pieces.

There is also another phenomenon that has been observed to occur due toseepage of resin into the hairline cracks separating the puzzle piecesin instances where the puzzle or tile pieces are made of relativelyabsorbent paper stock or similar material. In this connection, thecardboard or chip-board pieces will tend to absorb a certain amount ofthe resin adjacent their peripheral margins Where the original sheet ofpaper stock has been die-cut to form the multiplicity of individualpuzzle pieces. It has, therefore, been found that the relatively heavyimpregnation of each piece around its peripheral margins will tend todeepen the tone of color painted or lithographed on the upper surface ofthe puzzle. As a consequence, each puzzle piece looked upon individuallywill appear to have deeper tones of color around its periphery thantoward its center portions. This difference in color tone effect givesgreat depth and a three-dimensional effect to the end product.

A principal object of the present invention, therefore, is to provide amosaic and method of making same which can be made to appear as aremarkably realistic duplication of a polished mosaic tile work.

More specific objects of the invention are to provide a 3,l7 i,893Patented Mar. 23, 1965 simulated ceramic mosaic tile-like constructionthat is inexpensive to manufacture, that requires substantially littleskill, and that may be fabricated to form items of utility, particularlytable surfaces which because of their heavy overlayer or coating ofdurable plastic may be employed for indoor or outdoor use.

Further objects, features, and advantages of the present invention willbecome apparent upon reading the following detailed specification, inwhich:

FIGURE 1 shows in perspective one embodiment of the product provided bythe present invention.

FIGURE 2 shows in top elevation an enlarged section of the productillustrated in FIGURE 1.

FIGURE 3 shows a sectional side view of an enlarged segment of theproduct illustrated in FIGURE 1 and is taken along line 3-3 of FIGURE 2.

The present invention may be more easily understood by considering thepreferred embodiment as being composed of three major elementsdesignated by letters particularly as shown in FIGURE 3. These majorelements comprise a plurality of resin supporting members A, a base orsupporting surface B for said resin supporting members A, and a resinlayer C coated on the resin supporting members A. The resin supportingmembers A are disposed on base B in closely positioned relationship andthe resin layer C which covers a major portion of the surface of membersA imparts a ceramic tile-like appearance to resin supporting members A.Resin layer C also serves to bond resin supporting members A to eachother and to base B.

The resin supporting members A in the embodiment shown in the drawingsare conventional jig-saw puzzle pieces and are made out of cardboard.Piece 10 has a top 11, a bottom 12, and sides 13. There are, however, amultitude of suitable sizes and shapes for the resin supporting membersA. Thus, top 11 may be curved instead of fiat and in some instances thecurvature may accent and bring out the desired simulated ceramic effect.Piece 10 may similarly have straight sides instead of being irregularand interlocking as is true of jig-saw puzzle pieces 10. Theinterlocking nature of pieces 10 is particularly Well shown in FIGURE 2.The only requirement for pieces it is that they have enough surface areato support a sufficient quantity of resin capable of forming the resinconfiguration to be hereinafter described.

It has been found that a flat, relatively thin design is suitable forpieces 10. This design is found in the conventional jig-saw puzzlepieces 10. Thus, the size of conventional jig-saw puzzle pieces 10,which are generally about one inch across at the widest point on top 11and have a side 13 of about /8 inch in height, are suitable for use inthe present invention. It will be obvious to those skilled in the artthat the foregoing dimensions are subject to a great deal of permissiblelatitude.

Pieces 10 are assembled in conventional closely spaced substantiallyabutting interlocking relationship. This normally leaves an irregularchannel 14 or hair line crack defined by the adjacent sides 13 andlocated between all adjacent puzzle pieces 10. The function of irregularchannel 14 will be described later.

Base B is made from any desired material and is shown as a Woodensurface. It is contemplated that base or supporting surface B will bedesigned to just fit the overall outside perimeter of the closely spacedpieces 10 although variations in design to suit the individual areunlimited. Supporting surface B will generally be designed with the endpurpose of the simulated ceramic mosaic in mind. Thus, if it is to behung on a wall, base B would be some type of a frame. The embodimentillustrated in FIG- URE 1 shows the mosaic employed as the decorationfor a table top 15 having table legs 16 and 17 and two other legs notshown. Optionally, the completed mosaic is bordered by a molding 18which serves to protect the edges of the mosaic from being broken andalso to improve the overall appearance of the construction.

it should be pointed out that while the preferred embodiment employs abase or supporting surface B, constructions which do not have such abase are still to be considered within the scope of the presentinvention. For example, a construction having resin supporting membersand a resin coating of suflicient strength because of the type andthickness of resin employed, and therefore does not require an externalsupport or base, is contemplated.

Each of puzzle pieces has a section of a visual display such as asection of a design or an image visible on the top 11 thereof. When thepuzzle pieces 10 are disposed in interlocking and ordered relationship,the solved puzzle may be viewed and the total composed visual displayseen as illustrated in FIGURE 1. Puzzle pieces 10 are preferablydisposed on base B in a coplanar relationship. However, other specialrelationships are contemplated by the present invention such as may befound when employing a base B with a curving surface. It will also beobvious that pieces 10 be free of any design or image or other visualdisplay.

Resin layer C covers a major portion of the surfaces of pieces 10including substantially all of tops 11 and sides 13. The part of layer Cdisposed on top 11 of pieces 14 is present in the shape of a roundedcrown. This is due to the fact that resin layer C is thicker in thecentral portion 19 of top 11 than it is in the vicinity of theperipheral portions 20 of top 11. This differential thickness of layer Cin contact with top 11 results partially from the surface tension of thelayer C during the time it is being applied in the form of a liquid aswill be more fully described hereinafter. In addition, when resin layerC is in its initial liquid state, it tends to flow from peripheral areas29 of top 11 down into channel 14. This leaves less resin in theperipheral areas 20 than in the central portion 1h of top 11 and therebyproduces the foregoing differential thickness.

The configuration of a rounded crown present in that part of layer Cwhich is in contact with top 11 is responsible for creating the illusionthat pieces 10 are ceramic tiles. As a result, the completed puzzleshown in FIG- URE 1 appears to be composed of a plurality of ceramictiles and resembles a ceramic mosaic to an amazing degree.

Resin coating C has yet another important function. As previouslymentioned, the resin flows down channel 14. It also usually seeps to anappreciable extent beneath bottom 12 of piece 10 and thus issimultaneously in contact with bottom 12 and base B. The resin in theforegoing two locations serves to bond pieces 10 to each other and tobase B.

Besides assuming a rounded crown configuration on top 11 and thusimparting a simulated ceramic tile-like appearance to pieces 16, resin Ccreates the ceramic illusion in yet another manner. Sides 13 ofcardboard puzzle pieces 10 are porous and resin permeable as comparedwith the glazed top 11 which is relatively resin non-permeable. Whenresin C flows down channel It), a portion of resin C permeates throughside 13 and into the interior portions 21 of piece 10 proximate tochannel 14. The resin C present in interior portions 21 causes theappearance of puzzle pieces 10 to be deeper in color in the areas whereresin C is present. Thus, there is a color gradient between interiorportions 21 and the remainder of puzzle pieces 10. This color gradientis visible to the human eye and tends to increase the apparent depth ofindividual pieces 10, further heightening the illusion that pieces 10are ceramic tile-like.

In addition, resin coating C tends to cause top 11 of piece 10 itself tobecome crown shaped. This occurs as resin coating C dries and hardens,at which time it contracts the interior portions 21 where it haspermeated. The result is a shortening of sides 13 and the creation of acrown effect on top 11.

The foregoing simulated ceramic tile-like construction may be preparedby the method provided by the present invention. The construction may bemade by optionally providing a supporting surface or base as isdiscussed above. A plurality of resin supporting members are dis posedin closely positioned relationship and a coating of resin applied over asubstantial portion of the surface of the resin supporting members.

In the case of the preferred embodiment, the resin supporting membersselected are conventional jig-saw puzzle pieces and are disposed on asupporting surface which comprises a table top with legs.

The method of this invention is practiced, in the case of theillustrated construction, by applying at least one layer of atranslucent laminating resin over substantially all of the surface ofthe puzzle pieces. The result is the creation of a ceramic tile-likeappearance in the puzzle pieces.

As mentioned above, differential permeation of the resin in variousparts of the resin supporting members heightens the ceramic illusion.The desired degree and areas of resin permeation and its attendanteffect may be accomplished by the present method by preselecting theresin supporting members with this end in mind. Thus, by preselectingthe members for the portions of their surface which are porous and forthe degree of porosity of those porous portions, any desired effect maybe ob tained when practicing the present invention.

Any resin having the properties of being iiowable, preferably at roomtemperature, and which may then be cured to sufficient hardness to bedurable under the conditions of the intended use of the mosaic issuitably used. A group of suitable resins is herein referred to aslaminating resins to differentiate them from resins used for diverseother purposes including adhesives or in the eX- trusion of plastics tomake products of various shapes.

In particular it is preferred to use laminating resins of the polyestertype which may be cured at room temperature. One very suitable exampleis Laminac polyester resin 4116 which is manufactured by AmericanCyanamid Company. Laminac resins are thermosetting and are a group ofreactive polyester copolymers. They are supplied in the form of liquids.This resin and others of the same variety are designed to be catalyzedprior to being applied to the resin supporting members. Any of thecatalysts known in the art for such purposes may be used. Suitableexamples include the organic pproxides such as methylethyl ketoneperoxide and the ire.

The resin is applied in any manner which results in a layer being formedover a major portion of the surface of the resin supporting members. Itis preferred that the resin be so applied that it covers substantiallyall of the tops 11 and sides 13 of puzzle pieces 10 at least in the caseof when the construction of the preferred embodiment is made. When thisprocedure is followed, sufficient resin will necessarily flow beneaththe resin sup porting members to create a sufficiently strong bondbetween the resin supporting members and the base or supporting memberswhen one is used.

One suitable way of applying the resin in accordance with the presentmethod is to add the catalyst selected to a container containing theparticular resin selected. The catalyst and resin are then mixed and thecontents of the container poured in a continuing stream over the resinsupporting members. A small amount of the contents of the container isreserved. The resin is smoothed into a layer over the resin supportingmembers with a cardboard squeegee. The small portion of the reservedcontents of the container is then used to do any necessary touching upin the coating. The resin is then allowed to set or harden. Any bubblesthat may form are pricked with a pin and any parts of the supportingmembers that may float up are pushed down.

The length of time necessary for producing a hard surface will depend onthe particular resin chosen and Will usually be about one to three days.In most cases the time can be accelerated by subjecting the appliedresin to heat. After a period of about one month the surface will havehardened to the point where it is as hard as glass.

In the case of the preferred embodiment, the table top, legs, andmolding may be stained or varnished or otherwise decorated to suit theindividuals taste.

lthough the foregoing inventions has been described in some detail byway of illustration and example for purposes of clarity ofunderstanding, it is understood that certain changes and modificationsmay be practiced within the spirit of the invention as limited only bythe scope of the appended claims.

What is claimed:

1. A simulated ceramic tile mosaic construction comprising a singlelayer of a plurality of closely positioned resin supporting members anda continuous coating of resin over a substantial portion of the surfaceof said members, the coating over each member being thicker in thecentral portion than at the peripheral portions thereof to define arounded crown of resin thereover, and thereby to impart a ceramic tileappearance to said members.

2. A construction in accordance with claim 1 wherein said resinsupporting members are disposed on a supporting surface.

3. A simulated ceramic tile mosaic construction comprising a supportingsurface, a plurality of fiat resin supporting members disposed on saidsupporting surface in closely positioned substantially coplanarrelationship, and a continuous coating of laminating resin over a majorportion of the surface of said members including substantially all ofthe tops and sides of said members forming a ceramic tile curved top oneach of said resin supporting members.

4. A simulated ceramic tile mosaic construction comprising a pluralityof relatively thin, flat, resin supporting members each having a sectionof an overall visual display imprinted on its top surface, said resinsupporting members being disposed in closely positioned substantiallycoplanar relationship and in such a manner as to form an ordered totalvisual display composed of said display sections, and a coating oflaminating resin over a major portion of the surface of said membersincluding substantially all of the tops and sides of said members, thecoating over each member being thicker in the central portion than atthe peripheral portions thereof to define a rounded crown of resinthereover, thereby to impart a ceramic tile appearance to said members,

5. A construction in accordance with clainr 4 wherein said resinsupporting members are differentially resin permeable and said resin ispermeated through a part of said members thereby increasing the illusionof said members appearing tobe ceramic.

6. A simulated ceramic tile mosaic construction comprising a pluralityof jig-saw puzzle pieces having a portion of a visual display on oneside of each piece, a supporting surface for said pieces, said piecesbeing disposed on said surface in interlocking substantially coplanarrelaitonship in such a manner as to form an ordered total visual displayfrom said display portions, and a coating of translucent laminatingresin over substantially all of said pieces, the coating over each piecebeing thicker in the central portion than at the peripheral portionsthereof to define a rounded crown of resin thereover, thereby to imparta ceramic tile appearance to said pieces and to bond said pieces to eachother and to said surface.

References Cited in the file of this patent UNITED STATES PATENTS Re.20,607 Tomec Dec. 28, 1937 1,531,789 Jennings et al Mar. 31, 19251,997,500 Swarovski Apr. 9, 1935 2,156,566 Kirschraun May 2, 19392,214,387 Snyder Sept. 10, 1940 2,245,047 Odell June 10, 1941 2,572,269Maier Oct. 23, 1951 2,637,995 Mann May 12, 1953 2,668,328 Porter Feb. 9,1954 3,025,626 Schurnacher Mar. 20, 1962 3,056,224 Almy et a1 Oct. 2,1962

1. A SIMULATED CERAMIC TILE MOSAIC CONSTRUCTION COMPRISING A SINGLE LAYER OF A PLURALITY OF CLOSELY POSITIONED RESIN SUPPORTING MEMBERS AND A CONTINUOUS COATING OF RESIN OVER A SUBSTANTIAL PORTION OF THE SURFACE OF SAID MEMBERS, THE COATING OVER EACH MEMBER BEING THICKER IN THE CENTRAL PORTION THAN AT THE PERIPHERAL PORTIONS THEREOF TO DEFINE A ROUNDED CROWN OF RESIN THEREOVER, AND THEREBY TO IMPART A CERAMIC TILE APPEARANCE TO SAID MEMBERS. 